Karl--excellent post. If I may, is the material now available for any "additative" manufacturing process; i.e. 3-D printing, stereo lithography, etc etc. It certainly seems from your post the characteristics are very desirable and have definite applications. Just a thought.
Chain orientation in feedstock before machining can have a large effect on final dimensions. Machining top surfaces of extruded plate can cause internal stresses to release causing warp on a previously flat plate.
Mr Hebel has writtenn a useful article about the challenges found in machining some thermoplastics. All of the points that he made are certainly valid, and the suggested work-arounds will be helpful, no doubt.
But most of the challenges also exist when machining metal parts, except for the moisture absorbtion. The same tips apply when working to produce higher accuracy metal parts as well, although to a somewhat lesser extent. I just wanted to point that out to those who may need to give direction in the macchining of high accuracy parts.
Fifty-six-year-old Pasquale Russo has been doing metalwork for more than 30 years in a tiny southern Italy village. Many craftsmen like him brought with them fabrication skills when they came from the Old World to America.
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